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Abstract:

The present invention is directed to a high surface area fiber and method
for making the same. The fiber includes a co-extruded internal fiber and
an external sheath that is washed with a solvent to remove the
dissolvable external sheath, the resulting fiber having a longitudinal
axis and a cross-section, the cross-section having a middle region and
projections extending from the middle region.

Claims:

1. A method of making a high surface area fiber, the method comprising:
co-extruding an internal fiber and a dissolvable external sheath through
at least one plate, then washing the co-extruded fibers with a solvent to
remove the dissolvable external sheath, the resulting fiber having a
longitudinal axis and a cross-section, the cross-section having a middle
region and between 16 and 32 projections extending from the middle
region.

2. The method of claim 1, further comprising the step of melt spinning
the internal fiber and the dissolvable external sheath to form a
bicomponent fiber.

3. The method of claim 1, further comprising the step of forming a
textile product before washing to remove the dissolvable external sheath.

4. The method of claim 1, further comprising the step of binding the high
surface area fibers to form a non-woven fabric.

5. The method of claim 4, wherein the step of binding the high surface
area fibers to form a non-woven fabric further comprises binding using
thermal, chemical, or mechanical means or a combination thereof

6. The method of claim 1, further comprising binding the high surface
area fibers to form a woven fabric.

7. The method of claim 1, wherein the internal fiber has a specific
surface area between 80,000 cm2/g and 1,000,000 cm2/g.

8. The method of claim 1, wherein the internal fiber is a thermoplastic
polymer.

9. The method of claim 1, wherein the dissolvable external sheath is a
dissolvable polymer.

10. The method of claim 9, wherein the dissolvable polymer is polyactide
(PLA).

12. A winged fiber, the fiber comprising: a co-extruded fiber having an
internal fiber and a dissolvable external sheath; the internal fiber
having a longitudinal axis and a cross-section, the cross-section having
a middle region and a plurality of projections extending from the middle
region, the plurality of projections defining a plurality of channels,
the channels having a width between 200 nanometers and 500 nanometers;
and the dissolvable external sheath being removed from the internal fiber
by washing after the co-extrusion.

13. The fiber of claim 12, wherein the internal fiber has a specific
surface area between 80,000 cm2/g and 1,000,000 cm2/g.

14. The fiber of claim 12, wherein the internal fiber is a thermoplastic
polymer.

15. The fiber of claim 12, wherein the dissolvable external sheath is a
dissolvable polymer.

16. The fiber of claim 15, wherein the dissolvable polymer is polyactide
(PLA).

18. A method of making a high surface area fiber, the method comprising:
co-extruding a thermoplastic polymer internal fiber and a dissolvable
external sheath through at least one plate, then washing the co-extruded
fibers with a solvent to remove the dissolvable external sheath, the
resulting fiber having a longitudinal axis and a cross-section, the
cross-section having a middle region and a plurality of projections
extending from the middle region, the plurality of projections defining a
plurality of channels, the channels having a width between 200 nanometers
and 500 nanometers.

19. A method of making a high surface area fiber, the method comprising:
co-extruding a thermoplastic polymer internal fiber and a dissolvable
external sheath through at least one plate, then washing the co-extruded
fibers with a solvent to remove the dissolvable external sheath, the
resulting fiber having a longitudinal axis and a cross-section, the
cross-section having a middle region and a plurality of projections
extending from the middle region, and having a specific surface area of
more than 80,000 square centimeters per gram.

Description:

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This is a divisional application filed from U.S. patent application
Ser. No. 11/592,370 filed Nov. 3, 2006, which is incorporated herein by
reference.

DESCRIPTION

[0002] 1. Field of the Invention

[0003] The present invention relates generally to high surface area fibers
and textiles made from the same. Further, the present invention relates
to high surface area fibers made from a bicomponent fiber extrusion
process.

[0004] 2. Description of the Prior Art

[0005] Fibers capable of absorbing and filtering liquids or particles are
known in the art. Fiber surfaces are often treated chemically or
physically to enhance their ability to hold liquids or particles. For
instance, in order to increase the surface area of a fiber the surfaces
are made rough to create grooves and channels. Some absorbent fibers
known in the art are treated with hydrophobic or hydrophilic chemicals,
which affects fluid flow.

[0006] One such fiber that is used for absorption is the 4DG fiber
developed by and commercially available from Eastman Chemical Company.
Referring to the drawing of FIG. 1 is a cross-sectional view of the 4DG
fiber, also known as surface capillary fibers. The prior art fiber of
FIG. 1 discloses one set of at least three arms that project from one
side of the spine to define a first set of grooves, and a second set of
at least three arms that project from a second side of the spine to
define a second set of grooves. The arms and grooves of the prior art
fiber have an irregular geometry so as to create grooves that are deep
and narrow enough to transport fluids along the length of the fiber by
capillary action. Additionally, the prior art fiber of FIG. 1 has a large
denier which limits its use in certain applications for which nano-fibers
are required.

[0007] The 4DG fiber seeks to increase the depth of the grooves by
providing a fiber with a specific cross-sectional geometry. However,
there are several disadvantages to the 4DG fiber and other fibers having
a similar configuration. Many such fibers cannot be spun to fiber
diameters less than about 50 to 60 microns, thereby restricting their
potential applications. The minimum denier attainable with the 4DG fiber
is approximately 3. Furthermore, due to the large grooves between the
arms of the fiber, the arms often break during the spinning process. Such
fibers have a limited number of arms and grooves resulting in a
relatively low surface to volume ratio, which restricts the amount of
fluid that can be absorbed. Finally, due to the size and geometry of the
4DG fiber, the arms can easily interlock during fabric formation
resulting in dense and compressed materials, which diminishes its
filtration and absorption properties.

[0008] There have been many attempts in the past to create special fibers
with deep grooves or channels on the surface to promote surface capillary
properties. Such fibers utilize multiple legs, typically 8, to form deep
channels on the surface. The surface of these fibers can be treated with
appropriate treatments that accommodate and facilitate fluid flow more
readily and are therefore useful for fluid movement. Many of these fibers
have a higher degree of bulk density and are therefore suitable for
insulation applications. Since the arms can capture and trap particles,
they are further useful for filtration applications or for surface
treatments to activate the surface.

[0009] Fibers with surface grooves are produced using special spinnerets
as single component fibers. The fibers are extruded and melted,
delivering the molten polymer through spin beams and the spinneret
capillaries to form the desired shape. The fibers are then quenched upon
the exit from the spinneret and drawn subsequently to form a stronger and
finer fiber. However, because of the deep grooves or arms of the fibers,
the fibers cannot be made into normal fiber sizes that are preferred and
used by the industry. Most fibers used today are between 1 and 3 denier
per filament, however most fibers with the increased surface areas as
discussed above are currently typically available in 6 denier or larger.
Fibers with deniers of 6 or larger are extremely coarse, more difficult
to process, and are therefore, limited in their use.

[0010] Traditional single component round fibers are commonly used in the
art. The cross-sectional design of a single component round fiber is
typically a circle. One problem with single component round fibers is
that in order to increase the surface area of the fiber per mass, the
cross-sectional area also has to be reduced, requiring significant
reduction in diameter to produce higher surface areas. [0009] There is a
need for a fiber with an increased surface area, at least 2 to 3 times
the surface area of typical fibers known in the art, and with deep
grooves or channels on the surface to promote surface capillary
properties while maintaining a normal fiber size as used in the industry.
The present invention discloses a fiber with an increased surface area
and multiple surface channels, while maintaining a similar denier.

[0011] The present invention is provided to solve the problems discussed
above and other problems, and to provide advantages and aspects not
provided by prior fibers of this type. A full discussion of the features
and advantages of the present invention is deferred to the following
detailed description, which proceeds with reference to the accompanying
drawings.

SUMMARY OF THE INVENTION

[0012] An embodiment of the present invention includes a method of making
a high surface area fiber that includes co-extruding an internal fiber
and a dissolvable external sheath through at least one plate. The
resulting fiber is then washed with a solvent to remove the dissolvable
external sheath. The resulting fiber has a longitudinal axis and a
cross-section, the cross-section having a middle region and between 16
and 32 projections extending from the middle region.

[0013] Another embodiment of the present invention also includes a method
of making a high surface area fiber that includes co-extruding an
internal fiber and a dissolvable external sheath through at least one
plate. The resulting fiber is then washed with a solvent to remove the
dissolvable external sheath. The resulting fiber has a longitudinal axis
and a cross-section, the cross-section having a middle region and a
plurality of projections extending from the middle region, the plurality
of projections defining a plurality of channels that have a width between
200 nanometers and 500 nanometers.

[0014] Yet another embodiment of the present invention includes a method
of making a high surface area fiber that includes co-extruding an
internal fiber and a dissolvable external sheath through at least one
plate. The resulting fiber is then washed with a solvent to remove the
dissolvable external sheath. The resulting fiber has a longitudinal axis
and a cross-section, the cross-section having a middle region and a
plurality of projections extending from the middle region, and has a
specific surface area of at least 80,000 square centimeters per gram.

[0015] Thus, the present invention provides a high surface area fiber made
from a bicomponent extrusion process for woven and non-woven
applications.

[0016] These and other aspects of the present invention will become
apparent to those skilled in the art after a reading of the following
description of the preferred embodiment when considered with the
drawings, as they support the claimed invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1 is a cross-sectional perspective view of a prior art fiber.

[0018] FIG. 2 is a cross-sectional view of a fiber with an external
sheath, in accordance with one embodiment of the present invention.

[0019]FIG. 3 is a cross-sectional view of a single fiber, in accordance
with one embodiment of the present invention.

[0020] FIG. 4 is a cross-sectional view of a fiber without the external
sheath, in accordance with one embodiment of the present invention.

[0021]FIG. 5 is a cross-sectional view of the fiber having a circular
configuration, in accordance with one embodiment of the present
invention.

[0022] FIG. 6 is a cross-sectional view of a non-woven fabric, in
accordance with one embodiment of the present invention.

[0023] FIG. 7 is a cross-sectional view of a non-woven fabric of the prior
art.

[0024]FIG. 8 is a graph comparing the denier per filament versus the
specific surface areas for a round fiber, a 4DG fiber, and a fiber of the
present invention.

DETAILED DESCRIPTION

[0025] In the following description, like reference characters designate
like or corresponding parts throughout the several views. Also in the
following description, it is to be understood that such terms as
"forward," "rearward," "front," "back," "right," "left," "upwardly,"
"downwardly," and the like are words of convenience and are not to be
construed as limiting terms. Referring now to the drawings in general,
the illustrations are for the purpose of describing a preferred
embodiment of the invention and are not intended to limit the invention
thereto.

[0026] Referring to the drawings, FIGS. 2-4 disclose a cross-section of
the fiber of the present invention generally designated by the reference
numeral 10. As shown in FIG. 2, the fiber 10 generally comprises an
internal fiber 12 and an external sheath 14. The fiber 10 is generally
constructed from two different polymer compositions that can be extruded
in an oval cross-section, which allows for high processability.
Alternatively, the cross-section can be circular or other shapes as
desired. The extrusion process and the method of making the fiber 10 of
the present invention are described in greater detail below.

[0027] As further shown in FIGS. 2-4, the cross-section of the internal
fiber 12 has a generally winged-shape, or amoeba-like shape. The internal
fiber 12 has a middle region 16, which is the longitudinal axis 17 that
runs down the center of the internal fiber 12. The longitudinal axis 17
has a plurality of projections 18 that extend from the longitudinal axis
17, which are depicted in FIGS. 2-4. In the preferred embodiment, the
plurality of projections extend along the periphery of the longitudinal
axis 17. Alternative cross-sectional shapes, such as but not limited to a
circular-shape or the like, would have the middle region 16 formed as a
hub where the projections extend from the hub. In one embodiment, the
plurality of projections are uniformly spaced. The plurality of
projections 18 increase the surface areas and surface capillaries for a
single fiber. In the preferred embodiment, the plurality of projections
18 define a plurality of channels 20, as shown in FIG. 4. In one
embodiment, the plurality of channels 20 are uniformly spaced. The
channels 20 create a surface capillary portion along the length of the
fiber 10 that facilitates the absorption of liquids within the fiber 10.
Additionally, the channels 20 allow particles, such as debris and dirt,
to be picked-up and retained within the fiber 10. Thus, the fiber of the
present invention has a plurality of longitudinal capillary channels 21
that extend along the length of the fiber as shown in FIG. 3. The present
invention also drastically increases the surface area of the
cross-section of the internal fiber 12 due to the plurality of
projections 18. The increased surface area created by the internal fiber
12 depends on the number of segments that are used during the
manufacturing of the fiber 10, which is discussed in detail below.

[0028] Preferably, the channels 20 are nano-sized, having a width of about
200 nanometers. Alternatively, the channels 20 could be between 200
nanometers to 1000 nanometers. The width of the channels 20 can be
modified to fit different applications. The nano-sized channels of the
present invention allow the fiber 10 to be used in applications where
micro-filtration or micro-absorption is necessary. For example, certain
filtration mechanisms require a channel size of about 300 nanometers.
Because the channel size for each fiber can be regulated, the present
invention can be used to create a textile fabric having fibers with
different channel sizes. For example, a textile fabric such as a filter
could comprise fiber bundles having 200 nanometer channels and 500
nanometer channels. In one embodiment if the channels have a width of
about 200 nanometers there are about 32 projections 18 extending from the
middle section 16.

[0029] In the preferred embodiment of the present invention, the internal
fiber 12 is a thermoplastic polymer known in the art. Any number of
thermoplastic polymers can be used, such as but not limited to,
polypropylene, polyester, nylon, polyethylene, thermoplastic urethanes
(TPU), copolyesters, or liquid crystalline polymers.

[0030] In the preferred embodiment the cross-section of the fiber is
highly flexible and has a solid interior. Alternatively, in one
embodiment, the interior, or middle region part of the internal fiber is
a void. The void in the center forms an added channel for fluid flow.
FIG. 5 shows a cross-section of a fiber of the present invention missing
the middle region 16 of the internal fiber 12.

[0031] Alternatively, in another embodiment, the middle region 16 of the
internal fiber 12 can be formed into a circular configuration during the
extrusion process. This void allows the internal fiber 12 to be more
rigid and have more bending resistance because of the void in the center.
Additionally, the void in the center forms an added channel for fluid
flow. A fiber with a circular cross section with a void will have a lower
tendency to bend over itself.

[0032] FIG. 2 shows a cross-sectional view of the fiber 10 with the
external sheath 14. In the preferred embodiment the external sheath 14 is
a dissolvable thermoplastic, such as but not limited to, polyactide
(PLA), co-polyester (PETG), polyvinyl alcohol (PVA), or ethylene-vinyl
alcohol copolymer (EVOH). It is contemplated that any number of
dissolvable thermoplastics known in the art may be used as the external
sheath 14 in connection with the present invention. In the preferred
embodiment the external sheath 14 encompasses the internal fiber 12 as
shown in FIG. 2.

[0033] One aspect of the present invention is increasing the surface area
of the fiber, while maintaining the denier of the fiber between 1 and 3.
In the preferred embodiment, the denier of the fiber is about 1.0 to
about 2.0. However, alternatively, the denier of the fiber can range from
about 1.0 to about 20.0.

[0034] Denier is the unit used to measure the fineness of yams, and is
equal to the mass in grams of 9,000 meters of yarn. In the preferred
embodiment of the present invention, the specific surface area for a one
(1) denier fiber is about 28,000 and about 200,000 cm2/g. The specific
surface area in terms of cm2/g of a fiber is measured by the following
equation:

[0041] The specific surface area of the preferred embodiment of the
present invention is about 57-60 times greater than a typical 4DG fiber
known in the art. As shown in FIG. 8, the specific surface area of a
fiber of the present invention is significantly greater than a
traditional round fiber or a typical 4DG fiber having the same denier.
For example, a round fiber with a denier of 3 has a specific surface area
of 1653 cm2/g. A 4DG fiber with a denier of 3 has a specific surface area
of 4900 cm2/g. In contrast, a fiber of the present invention with a
denier of 3 has a specific surface area of over about 80,000 cm2/g. In
one embodiment of the present invention, the cross-section of the
internal fiber has a specific surface area of about 140,000 cm2/g or
higher. The present invention achieves a large specific surface area
because of the unique geometry of the plurality of projections and the
plurality of channels. While the preferred embodiment of the present
invention has a fiber denier of about 1.0 to about 2.0, the above
comparison was chosen because the 4DG fiber is not capable of being
produced with a denier below 3.

[0042] In the preferred embodiment, the internal fiber 12 has a
cross-sectional length of about 20 micrometers and a cross-sectional
width of about 10 micrometers, which yields a fiber having a denier of
about 1.5. Denier refers to the linear density of the fiber and is the
weight in grams for a fiber measuring 9,000 meters. In another
embodiment, the internal fiber 12 has a cross-sectional length of about
10 micrometers and the width of about 10 micrometers. The internal fiber
12 of the present invention may have a cross-sectional length of about 1
micrometer to about 100 micrometers and a cross-sectional length of about
1 micrometer to about 100 micrometers. Alternatively, in another
embodiment of the present invention the fiber could have a denier of 3 or
more, which would provide larger fiber with significantly large surface
areas.

[0043] The method of making the fiber of the present invention uses
extrusion techniques known in the art. Typically, bicomponent fibers are
formed by coextruding or, extruding two polymers from the same spinneret
with both polymers contained in the same filament or fiber. The extrusion
process forces thick, viscous polymers through a spinneret to form
semi-solid fibers. In the preferred embodiment of the present invention,
the extrusion system will form the fibers as described by directing and
channeling the two polymers appropriately, resulting in a more uniform
shape. The number of holes on the plates correspond to the number of
segments present in the fiber. These filaments are then solidified. The
preferred embodiment of the present invention uses melt spinning to form
the fibers, however other methods known in the art can be used. For
example, a segmented pie extrusion system can be used to form fibers with
projections extending from the longitudinal axis by a careful selection
of the two polymers and control of the extrusion process.

[0044] The method of making the preferred embodiment begins by extruding a
bicomponent fiber comprising a thermoplastic polymer, the internal fiber,
and a dissolvable thermoplastic polymer, the external sheath. The
bicomponent fiber is extruded through a spinneret having any number of
desired holes and cross-sectional shapes. In the preferred embodiment the
cross-section of the spinneret is oval for high processability,
alternatively a round cross-section can also be used, or other desired
shapes.

[0045] Alternatively, the final cross-sectional shape of the fiber, the
winged-shape as discussed above, is determined by the number of segments
formed from the extrusion process. The segments resemble pie-pieces,
called a "segmented-pie" bicomponent fiber. Typical fibers of the prior
art are formed from 16 segments, however in order to achieve the high
surface area cross-section of the present invention, the fiber must have
at least 4 segments.

[0046] In one embodiment of the present invention, the extruded
bicomponent fiber has at least 4 segments. Alternatively, in another
embodiment of the present invention the winged-shape cross-section of the
internal fiber yields extremely high surface areas because it is formed
from a bicomponent fiber having 64 segments. A caterpillar-like shape, as
shown in FIGS. 2-4, was an unexpected result generated by a 64
segmented-pie extrusion. It is difficult to form a bicomponent fiber
having more than 24 segments and the prior art fibers are limited in the
number of segments they can have.

[0047] One way to control the shape and the size of the segments is by
changing the temperature, viscosity, or pressure of the bicomponent fiber
during the extrusion process. Melt spinning allows fibers to be extruded
from the spinneret in different cross-sectional shapes, such as round,
trilobal, pentagonal, octagonal, and other shapes. The bicomponent
segments of one embodiment of the present invention resemble a segmented
pie having anywhere up to 64 pie segments. In the preferred embodiment
the segments alternate between the internal fiber and the dissolvable
external sheath. It is important that the segments alternate because once
the external sheath is washed and removed, the remaining segments define
the plurality of projections that form the basis for absorption and
filtration. The number of projections is directly proportional to the
total surface area generated. Therefore, fibers with precise and
pre-determined surfaces can be formed.

[0048] In a preferred embodiment, after the bicomponent fiber is extruded
and melt spun, the bicomponent fiber can be formed into a textile
product. Alternatively, the textile product comprises fiber media that is
made of a bicomponent fiber. The bicomponent fiber can be bonded together
to form a nonwoven fabric, such as a filter. Alternatively, the
bicomponent fiber can be formed into a woven fabric, such as a garment.
One of the advantages of the present invention is that the external
sheath does not have to be removed until after the textile media is made.
This enhances handling of the fiber and reduces costs associated with
manufacturing. FIG. 6 shows a non-woven fabric of the present invention
and illustrates how the winged-shaped fibers assemble together. As shown
in FIG. 6, the fibers can be compressed closely together to form bundles
without interlocking when they are placed adjacent to each other due to
the geometry of the fiber and the size of the channels. Additionally,
because the textile fabric can be constructed when the external sheath is
still on, the sheath further prevents the fibers from interlocking with
one another. FIG. 7 shows a prior art fabric in which the fibers
interlock. Because the fibers of the present invention do not interlock
like other fibers known in the prior art, the effectiveness of the
channels of the present invention is not compromised and remains
available for absorption or filtration. The external component can be
removed after the final product is formed. Therefore, the fibers of the
present invention and their projections cannot interlock.

[0049] Once the textile product is formed, the fabric is washed with a
solvent such as, but not limited to, NaOH, acids or in the case of water
dispersible polymers such as Exceval, water is used in order to remove
the soluble external sheath. Alternatively, the bicomponent fiber can be
washed prior to forming the textile product if desired.

[0050] In order to form the nonwoven fabric of the present invention, the
fibers can be bonded by using several different techniques including
thermal, chemical, or mechanical bonding. In one embodiment, the nonwoven
fabric is formed by using hydroentanglement, which is a mechanism used to
entangle and bond fibers using hydrodynamic forces. Alternatively,
nonwovens can be created by needle punching which mechanically orientates
and interlocks the fibers of a spunbound or carded web. Needle punching
is achieved with thousands of barbed felting needles repeatedly passing
into and out of the web. Needle punching and hydroentanglement form a
dense structure so that when the external sheath is removed, the wings
will release in place forming a structure with high permeability. The
ultimate application of the fabric will determine which bonding technique
should be utilized. For example, if the nonwoven fabric is to be used for
filtering large particles, it can be made using spunbound fibers that are
randomly interlocked fibers, but not woven. If the non-woven fabric is
needed to filter smaller particles, then it can be made from melt blown
fibers, uses high velocity air or another appropriate force to bind the
fibers together. Alternatively, filaments can be extruded, and said
filaments can be crimped and cut into staple fibers from which a web can
be formed and then bonded by one or more of the methods described above
to form a nonwoven. Same staple or filament fibers can be used to form
woven, knitted or braided structures as well.

[0051] In another embodiment of the present invention, staple nonwoven
fabrics can be constructed by spinning the bicomponent fiber and cutting
the length of the fiber into short segments and put into bales. The bales
are then spread in a uniform web by a wetlaid process or carding, and are
subsequently bonded by thermo-mechanical means as known in the art

[0052] The fiber of the present invention can also be used to manufacture
traditional woven fabrics for use in garments and the like. Because the
fibers of the present invention are strong, they can be used in
traditional knitting and braiding techniques without compromising the
integrity of the fiber.

[0053] Although numerous fibers are known in the art, the present
invention discloses a high surface area fiber with a small denier that
can be used in application for both woven and non-woven fabrics. The
fibers of the present invention have higher thermal insulation
capabilities than traditional fibers known in the art, and form improved
filtration mediums. Furthermore, the fibers of the present invention are
stronger, more flexible, and more breathable. As discussed above, because
the winged-shaped fibers are compression resilient, the channels are not
obstructed and have greater capillary/wicking abilities, as well as
absorption capabilities. Additionally, these fibers have the ability to
capture nano-sized particles. Because the fibers of the present invention
are strong and have shear resistance, the fibers can withstand high
pressures and can be used in liquid filtrations as well as demanding
aerosol filtration applications requiring high pressure. As such, the
present invention provides for a high-efficiency low-pressure drop filter
constructed from woven or nonwoven fabrics or fibers.

[0054] There are numerous applications of the present invention. In one
example the present invention can be used in traditional woven
applications, such as wicking garments, thermally insulating garments,
comfort garments, sportswear and camping wear. In another example, the
present invention can be used in non-woven fabrics to produce filter
media to filter liquids or air for cleaning rooms. In yet another
example, the present invention can be used with traditional round fibers
to yield multi-layer fibers that can be combined using a spinneret or
combined later in the manufacturing process. Combining or sandwiching the
fibers of the present invention with traditional round fibers allows a
single product to have multiple physical properties, and is cost
effective.

[0055] The present invention can also be used for improved wipe materials.
In typical applications wipes are primed with liquids before use, such as
in baby wipes. However, the present invention allows the ability to
create a wipe product that will pick up dirt and dust particles without
leaving behind any particles because the liquid in the channels of the
fibers remains there while still dissolving and aiding the clean-up
process. Additionally, the present invention can be used for hygiene and
acoustic materials, thermal insulation, geotextile materials,
construction materials, and compressive performance materials such as
seat cushions and mattresses.

[0056] Certain modifications and improvements will occur to those skilled
in the art upon a reading of the foregoing description. The
above-mentioned examples are provided to serve the purpose of clarifying
the aspects of the invention and it will be apparent to one skilled in
the art that they do not serve to limit the scope of the invention. All
modifications and improvements have been deleted herein for the sake of
conciseness and readability but are properly within the scope of the
following claims.